Rapid diffusion occurs between Al and Zn coating on HSLA steel during USW. A characteristic diffusion pattern forms at higher welding energy levels. Squeezed-out AlZn eutectic and Zn exhibit a brazing effect. Tensile lap shear strength is higher in Al-to-galvanized steel than Al-to-Al joints. Fatigue life is longer in the joint made at 2000 J than that made at 1000 J.